Hi! I'm new to FMEA and have read up a bit of FMEA. I was wondering if anyone could provide a PFMEA sample sheet for surface mount. We're a OEM manufacturing memory and I have no idea how to start doing the PFMEA. I know the foamt, but do not know how to categorise as it seems I'm into component level...

Hi! I'm new to FMEA and have read up a bit of FMEA. I was wondering if anyone could provide a PFMEA sample sheet for surface mount. We're a OEM manufacturing memory and I have no idea how to start doing the PFMEA. I know the foamt, but do not know how to categorise as it seems I'm into component level...

Welcome to the Cove :bigwave:

I can't give you an example but I can ask you a couple questions. I have no experience in Surface Mount Technology but if you're stuck with me to help out, you will need to help walk me through your process. I know it involves soldering or radiation of some type to adhere the components, some type of heat treat, and some kind of wash, but that's about the extent of my "knowledge".

* Have you/your team prepared a Process Flow Diagram (from "front door" to "back door"?
* Have you/your team decided whether to base your PFMEA on product characteristics, process characteristics, or both?
* Have you/your team looked at each step in your process and identified how the process can fail to deliver the required product characterisitics? or meet the required output parameters of the process step?

I'm not sure I understand what you mean by "it seems I'm into component level". Are you producing the components or assembling them to the board or both?

Welcome to the Cove :bigwave:

I can't give you an example but I can ask you a couple questions. I have no experience in Surface Mount Technology but if you're stuck with me to help out, you will need to help walk me through your process. I know it involves soldering or radiation of some type to adhere the components, some type of heat treat, and some kind of wash, but that's about the extent of my "knowledge".

* Have you/your team prepared a Process Flow Diagram (from "front door" to "back door"?
* Have you/your team decided whether to base your PFMEA on product characteristics, process characteristics, or both?
* Have you/your team looked at each step in your process and identified how the process can fail to deliver the required product characterisitics? or meet the required output parameters of the process step?

I'm not sure I understand what you mean by "it seems I'm into component level". Are you producing the components or assembling them to the board or both?

Hi Bill! First of all...a big thank you to replying to this thread! Some heads up of the SMT process:

It includes solder paste printing on a printer, then surface mount components like caps and res and ICs on SMT machines and finally going into a hot air reflow oven to "bake" the solder paste so that it harderns into electronic PCB that we see commonly.

We have prepared a process flow diagram. But, I'm not sure what you mean by front to back door. Do you mean raw materials received from store, get processed and sent back as finished product? If so, then our diagram does not include that. What we've drawn up is only the process for the manufacturing (SMT) part.

What is the difference between PFMEA based on product characteristics and process characteristics? I think we tried to do one based on products. Thats why I wrote we could be into component level FMEA.

We've reviewed the process and listed down the possible failure at each step.

Sorry for asking so many questions as we're new to this FMEA thingy. I really appreciate any help. Thanks. :)

Let's start with the "front" to "back" door. You purchase material and or components ("front" door). Do you have any type of receiving inspection? This should be addressed in the Flow Diagram, PFMEA, and Control Plan. If your automotive customer(s) follow the AIAG guidelines, the receiving step needs to be depicted in all 3 documents - whether there are Failure Modes and Controls identified or not. At the other end ("back" door) you need to identify the steps your shipping dept goes through to loading the truck.

Can you share your Process Flow Diagram? It would make this a bit easier for me to visualize what you are doing.

Regarding the product or process based approach - We employ a product approach. A Failure Mode in our PFMEAs is a nonconformance measureable on the part/product. The Failure Causes are the things in our processing that produce the nonconformance to the part. As an example, an as cast hole diameter can be oversized or undersized (two separate Failure Modes). The Failure Causes are those settings in our die casting process that could be attributed to the out of spec. condition (hot oil temperature, hold time, lube spray time, water flow setting, etc.).
If we were to use the process based approach, the Failure Modes would be hot oil temperature too hot/cold, hold time too long/short, lube spray time too long/short, water flow set too high/low, etc. The Failure Causes would then address how those modes could occur. The product specs. would then be identified in the Effects column. Don't get confused. The product based approach is just our preferred method due to our software (which I rave about at every opportunity).

Am I helping a little bit? Your Flow Diagram and just a partial list of some of your Failures would help me a lot if we are going to get into the nuts and bolts of addressing your process.

Later :bigwave:

Hi...Definately appreciate all the help you've given me. I've attached the process flow chart for your reference. Pls give some pointers. Thanks!

I'll look it over during the weekend and get back by Monday.

Have a good one.

No worries. Take your time. You have a good weekend too. :)

Hi Joe,

This may be a bit late as I've just came across your thread, however see attached example of a SMT FMEA I put together a few years back when working in automotive electronics.

Rgds

Robert

Hi! I'm new to FMEA and have read up a bit of FMEA. I was wondering if anyone could provide a PFMEA sample sheet for surface mount. We're a OEM manufacturing memory and I have no idea how to start doing the PFMEA. I know the foamt, but do not know how to categorise as it seems I'm into component level...

Hello Joe, I am also a new comer in Cove Forum. Although I have worked in Electronic Industries for more than 20 years, and also as an FMEA instructor, I have not involved in the development of a process FMEA for SMT processes. If I come across one , will be glade to share it with you. I think the attached files in Cove Forum contained lots of information on FMEA.

I hope, the attached several files from my personal resources do help. Let me know if you need any information on FMEA methodology.

Anyway, it's a pleasure to know you

Eric Ng

(Retired QA Manager, and Training Consultant)